Crimping tool with a pair of multisurfaced die plates



Aug. 25, 1959 w. M. WERNER 2,900,854

CRIMPING TOOL WITH A PAIR OF MULTI-SURFACED DIE PLATES Filed Au zs, 195'? 2 Sheets-Sheet l 46 INVENTOR. 'WQ' e1 Aug. 25, 1959 w, WERNER 2,900,854

CRIMPING TOOL WITH A PAIR OF MULTI-SURFACED DIE PLATES Filed Aug. 29, 1957 2 Sheets-Sheet 2 INVENTOR.

WQHET mble'rnc'r BY am r 11? nited States Patent 2,900,854 CRIMPING TOOL WITH A PAIR oFMULTI SURFACED DIE PLATES Walter M. Werner, Sharon Hill, Pa, assignor to AMP Incorporated, Harrisburg, Pa.

This invention relates to crimping tools, particularly of a type intended for use in crimping electrical connectors and terminals.

It is common practice in the electrical arts to attach a wire to a connector or a terminal by crimping a cylindrical ferrule portion of the connector or terminal onto the wire. Electrical connections of this type oifer many advantages, among which are the ease with which they can be made, their superior electrical and mechanical properties, their durability and resistance to adverse eifects such as corrosion and vibration, and the fact that they can be formed without the use of heat as is required for soldered connections.

The formation of a crimped electrical connection in accordance with the present teachings of the art requires that the size of the wire and the size of the connector be correlated and a connector having the proper ferrule size must be used for each wire size. Furthermore, the ferrule must be crimped. with properly engineered tooling and the dimensions of the crimping dies must be correlated with the size of the ferrule which is being crimped. Good quality crimped connections cannot, then, be made carelessly but must be formed by. the use of ferrules and crimping dies which are judiciously selected with reference to the size of the wires involved.

Where large numbers of crimped connections involving only a few wire sizes are being made, the necessity of careful selection 'of theproper ferrule size and die size is not a disadvantage, but in those instances where wires or cables of widely varying sizes are crimped and a relatively small number of crimped connections are made, this requirement of proper die size tends todiscourage the use of crimped connections. Obviously, the advantages of crimped connections can, under some circumstances, be offset by the expense of having available several sets of dies, which are seldom used, and the inconvenience of changing the .die set for the purpose of making a relatively small number of crimped connections.

An object ofthe present invention isto provide a crimping tool capable of crimping terminalsof widely varying sizes thereby to permit its use in making crimped connections with wires of varying sizes." A further object is to provide a unitary and self-contained device which can be rapidly adjusted fora given ferrule size without the removal or the replacement of dies or other interchangeable parts. A more specific object is 'to provide a pair of die plates. each-having: multiple pairs of die surfaces arranged such that one pair of die surfaces of one of the plates is cooperable with more than one pair of die surfaces on the other of the plates. Further objects and attainments of the invention will, be apparent from the followingydescription and from the. annexed drawings in which: M. r 1..

Figures 1 and 2 are plan views of a pair of die plates in accordance with theinvention; H

Figures 3, 4, 5, and 6 illustrate the various cooperative relationships of the die plates of Figures 1 and 2 for crimping ferrules of varying sizes;

Figure .7 is a fragmentary perspective view of a tool in accordance with the invention; 0

Fig. 8 is a perspective view of a crimped connection between a terminal and a wire formed by the die set of the instant invention;

Figure 9 illustrates the crimping of an alternative type of terminal; 0

Figures 10 and 11 show an alternative form of the invention; and e Figure 12 shows a further alternative form of the invention.

In accordance with a preferred embodiment of the invention, I provide a pair of die plates 2, 4 which are mounted for rotation on stub shafts 6,'8 and which provide openings as shown at 10 and 12 to facilitate locking the plates in a given position relative to these stub shafts. Plate 2 has edges 14 which would intersect, if projected to their points of intersection, to define a square. Die stations indicated by A, B, C, D, E and F are located around the sides of plate ,2 and impart to the plate the appearance of an irregular polygon having reentrant surfaces at spaced locations along its edges. At station A, die surfaces 16a, 16b extend inwardly of their respective sides 14 and intersect these sides at an angle of These die surfaces are further characterized in that they are of substantially the same length and intersect each other at an angle of 90. It will be apparent from the drawing that these relationships are achieved by virtue of the fact that each of the surfaces 16a, 16b intersects its respective side 14 of plate 2 at points which are equidistant from the intersection of the projections of the same two of the sides 14. In other words, these die surfaces define two sides of a square, the other two sides of which wouldbe defined by the projections of the adjacent sides 14 of the die plate itself. At station D of plate 2, two similar die surfaces 22a, 22b extend inwardly from adjacent sides of the plate and these surfaces have the same relationship to each other and to their respectivesides of the plate 2 as do the surfaces 16a, 16b, although, as is apparent from the drawing, the surfaces 22a, 2% are somewhat shorter than the: surfaces 16a, 16b;

Stations B and C are located adjacent to each other at one of the remaining apices of plate 2 and provide die surfaces 18a, 18b and 2012,2011 respectively. Surfaces 18a and 20b extend at right angles to the adjacent one of the sides 14 while surfaces 18b; 20a extend substantially normally of each other and are separated by a surface 11. The remaining die surfaces at E and F, 24a, 24b, 26a, 26b are somewhat similar to the die surfaces at B and C, although these surfaces at E and F have dimensions which are different from the dimensions of the die surfaces at Band C and are separated by a notch 25 rather than a fiat surface. Plate 4 provides sides 28 which, like, plate 2, formthe sides of a square and die surfaces are provided atstations G, H, I, J, and Kat spaced locations around these sides. At stations G, H, and K die surfaces 30a,f30b, 3201, 32b, ,and34a, 341) are provided all of which are substantially similar to die surfaces at A and D of plate 2. It should be notedthat the surfaces 32a, 32b at station G are of substantially the same length as the surfaces 16a, 16b of station A while the surfaces at H and: K are of intermediate lengths, smaller than the surfaces 32a, 32b and larger than the surfaces 2251,2212. Stations I and I provide surfaces 36a, 36b and 38a, 38bwhich are substantially similar to the surfaces at stationsB and C.

Referring now to shown in Figure 3; The die-plates may be mounted on anysuitable tool or press in such manner that they can be moved toward or away from each other as described below, and Figure 3 shows the die plates in their meeting relationship when the tool is closed to bring the die enter between the surfaces 32 on plate 4. Additional sizes offerrules can be crimped if the die surfaces H or K of 'plate 4 are brought into engagement with surface A. in plate 2, of these latter combinations not being specifically illustrated in view of the fact that the principle of the nesting and meeting die surfaces is illustrated in Figures 3 and 4.

In Figure 5 it can be seen that surfaces F, E of plate 2 can be brought into engagement with the die surfaces at I, J of'plate 4 for crimping ferrules of somewhat smaller sizes than can be accommodated by any combination of the surfaces A, D, K, G and H. The F--I combination is adapted to crimp a relatively large ferrule than the EJ combination when the dies are in the orientation of Figure 5. Figure 6 shows the arrangement when die surfaces at C and B on plate 2 are brought into engagement with the surfaces at I and I on plate 4. This arrangement accommodates additional smaller sizes of ferrules than can be crimped with the larger die sizes.

In the foregoing description of plates 2 and 4 no specific dimensions for the various die surface or the die plates themselves have been recited. It is to be understood that the dimensions will be selected with reference to the size range of the terminals which will be crimped in the tool, and that varying ferrule size ranges might be crimped by one set of die plates depending upon the .size of the plates and the depth of the various die surfaces provided thereon. The general principles of the invention require, however, that in the case of a square die plate, as in the previously described embodiment, the die surfaces should extend at right angles to the edges of the die plates and for each pair of die surfaces the length of each surface should be substantially equal to the length of the other. By virtue of this principle, the largest set of die surfaces of one of the plates (e.g. the surfaces at A of plate 2) will meet or nest with more than one set of die surfaces of the other plate (the surfaces G, H, and K of plate 4).

Referring now to Figure 7, and advantageous tool for the die set previously described is shown to comprise a pair of handles 54 which are pivoted together at their ends 56 for movement towards and .away from each other, such movement being limited by the provision of stop means shown at 55. Adjustable shoes or carriers 58 are pivoted as at 57 to the handles adjacent the ends and levers 40 are in turn pivoted at 64 to these their upper ends and are connected together by means .of v a link 50 and pins 52. Die-plates 2, 4 are mounted on the levers between the ends of extension plates 42 by the previously described pins 6, 8. In order to secure these pins position and retain the plates between the plates 42, washers or the like 48 are affixed as by upsetting the ends of pins 6 and 8. Removable locking pins 46 extend through each of the plates 42 and are such diameter as to extend through the openings 10, 12 in plates 2, 4 to lock the die plates in a given position relative to the plates 42.

In use, when a crimped connection is to he made, the desired combination of die surfaces on the plates 2, 4 is selected and the plates are rotated so that the desired surfaces are in opposed relationship to each other. The plates are then locked in position by means of the pins 46 and the handles are moved relatively away from each other to position plates. 2, 4 in spaced-apart relationship. Thereafter the stripped end' 66 of the conductor 68 is inserted into the ferrule 70 of a connector such as the connector shown in Figure 8 having a ring tongue 72 on its end. The connector is then positioned between die plates 2, 4 and the handles 54 are moved relatively towards each other to crimp the ferrule onto the stripped end of the conductor. With the embodiment described thus far, and with the die plates 2, 4 a crimp having a square cross section is produced as shown in 74 in Figure 8. Regardless of the size of the ferrule crimped, a'crimp having a square cross section is produced although, as well be explained below, with alternative embodiments the cross section of the crimp can depart from that of the square.

It should be noted that where a linkage system as shown in Figure 7 is used in conjunction with die plates as shown in Figures 1 and 2, the dies should be pivoted in position such that the two large dies (at stations A and G) will be against each other as shown in Figure 3 when the handles are closed and the stops 55 are against each other. If the parts are arranged in this manner, the die surfaces at K and H will also mate and nest with the die surfaces at A and the die surfaces at D will mate and nest with. those at G. However, if the surfaces at D are placed in opposition to those at either H or K it will be found that the handles cannot be completely closed for the reason that the dies cannot move towards each other to the same extent as is otherwise the case. Since the handles cannot be closed before the dies are brought into meeting and nesting relationship, the maximum force cannot be exerted. If the die plates are mounted in a simple press or in a straight action type hand tool, the

surfaces H and K can nest with the surface D to accommodate additional size ranges.

Crimping tools in accordance with the invention are "adapted to the crimping of flag type terminals as .well

as the more conventional types such as the ring-tongue of Figure 8. As shown in Figure 9, a flag type terminal having a ferrule 73 and a laterally extending flag portion 75 can be positioned between the appropriate dies of plates 2, 4 such that the surface of the flag portion extends along one of the edgesof one of the dies. The ferrule can be crimped notwithstanding the fact that flag portion 75 prevents complete closure of the dies by virtue of the resilience of the tool. a

The principles of the invention are applicable to die plates which depart from the square configuration shown in Figures 1 and 2 In Figures 10 and 11, there is shown a pair of die plates 76 which have sides conforming to Y the sides of equilateral triangles. In this case, the surin ferrules to be crimped with the two die plates.

ure 12 shows a further modification in which the die plates take the form of regular pentagons and the die surfaces 84 and 86 extend inwardly from the apices at angles equal to the angles between the adjacent sides. Again, any one of the die surface pairs of one of the plates 82 will mate or nest with more than one pair of die surfaces on plate 84. Figures -12 illustrate that the principle of the invention is applicable to any regular polygon and that to achieve the objects of this invention, the several die surfaces of each polygon must extend inwardly at the same angle with respect to the adjacent polygon side as the angle between intersecting Sides of the polygon. Of course it becomes impractical to use polygons having an unduly large number of sides and the preferred embodiment of Figures 1 and 2 will accommodate a wide range of ferrule sizes particularly when irregular die surfaces as at B and C are included with the die surfaces such as those at A and B.

While I have shown and described preferred embodiments of my invention obvious modifications might be made thereto within the scope of the intended claims.

I claim:

1. A tool for crimping electrical connectors of varying sizes comprising a pair of die plates each having portions of sides of a regular polygon and providing a plurality of pairs of reentrant die surfaces at apices of said polygon, each die surface intersecting a side of said polygon at an angle equal to the angle of the polygon whereby a pair of die surfaces of one of said die plates will mate with more than one pair of die surfaces of the other one of said plates, and means for moving said die plates towards and away from each other.

2. A tool for crimping electrical connectors of varying sizes comprising a pair of die plates each having portions of sides of a regular polygon and providing a plurality of pairs of reentrant die surfaces at apices of said polygons, each die surface of each pair extending inwardly of its side at the same distance from the included apex as the other die surface of the same pair, and different pairs of die surfaces extending inwardly at varying distances from their respective apices whereby, one pair of die surfaces of one of said die plates will mate with a plurality of pairs of die surfaces of the other of said plates.

3. A tool for crimping electrical connectors of varying sizes comprising a pair of co-planar die plates and means for moving said die plates towards and away from each other, said die plates having sides forming portions of similar regular polygons, each of said die plates providing on at least some of its apices a pair of reentrant die surfaces, each die surface of each pair being spaced from the included apex by substantially the same distance as the other die surface of the same pair, dliiferent pairs of die surfaces being spaced different distances from their respective apices, and each die surface intersecting its adjacent side at an angle substantially equal to the included angle between adjacent sides of said die plates, whereby a pair of die surfaces of one of said die plates will mate with any pair of die surfaces of the other of said die plates.

4. A device as set forth in claim 3 wherein said sides of the die plates form portions of the sides of a square.

5. A device as set forth in claim 3 wherein said means for moving said die plates towards and away from each other comprises a pair of levers each having a handle connected thereto, whereby upon movement of said han- .dles said levers are moved towards and away from each other, each of said die plates being rotatably and lockably mounted in one of said levers whereby a selected pair of die surfaces of one of said die plates can be brought into engagement with a selected pair of die surfaces of the other of said plates.

6. A crimping tool for crimping electrical connectors of varying sizes comprising a pair of die: plates, said die plates having sides which form portions of sides of similar regular polygons, a plurality of pairs of reentrant die surfaces at the apices of said plates, each die surface intersecting its adjacent side of its plate at an angle substantially equal to the polygon angle of said plates, each die surface of each pair being spaced from its adjacent apex by substantially the same distance as the other die surface of the same pair and different pairs of die surfaces being spaced from their included apices by different distances, a carrier for each of said die plates, handles concatonated with said carriers to move said die plates towards and away from each other, and said die plates being rotatably mounted in said carriers whereby selected pairs of said die surfaces can be brought into opposed relationship to permit crimping of varying sizes of terminals upon actuation of said handles.

References Cited in the file of this patent UNITED STATES PATENTS 1,321,208 Hinnershitz Nov. 11, 1919 1,670,201 McGary May 15, 1928 2,086,400 Brenizer July 6, 1937 2,639,754 Macy -1 May 26, 1953 2,729,995 Friedman et al. Jan. 10, 1956 

